GREATER CINCINNATI/NORTHERN KENTUCKY — INTERNATIONAL AIRPORT (CVG) — RELOCATION OF SR 20 AROUND THE FACILITY
Sector
Airport Construction
Client
Cincinnati/Northern Kentucky International Airport
Location
Hebron, KY
State
Kentucky
Status
Complete
By the Numbers
Metrics
700K CY
Excavation
20K CY
Structural Concrete
150K CY
Shot Rock Excavation
7,000 LF
24″ Sanitary Sewer (up to 35’ deep)
550 FT
Multi-Lane Auto Tunnel Constructed Under a New Runway
30K SF
MSE Wall
2
Bridges
2.3M LBS
Reinforcing Steel
Challenge
The schedule-critical relocation of SR 20 around CVG International Airport required ESW to complete a complex roadway, bridge, utility, and tunnel construction program within a non-negotiable 400-day timeframe. The challenge was intensified by massive rock excavation, stringent FAA requirements, and severe winter conditions, all while maintaining progress on a project supporting the airport’s ongoing expansion.
Solution
ESW self-performed the project’s major civil and structural work, leveraging innovative construction approaches, rigorous mass-concrete controls, and efficient project coordination to meet the airport’s 400- day schedule and stringent FAA requirements. .
Project Scope
E.S. Wagner served as the prime contractor for the 1.3-mile, schedule-critical relocation of Kentucky State Route 20 around the Greater Cincinnati/Northern Kentucky International Airport as part of the airport’s expansion. The project included more than 700,000 cubic yards of excavation, two 120-foot precast I-beam bridges, and over 7,000 feet of deep sanitary sewer installation. Its centerpiece was a 550-foot-long, four-lane tunnel engineered to support both roadway traffic and commercial aircraft loads above. Construction required extensive drilled shaft foundations, 2.3 million pounds of reinforcing steel, mechanically stabilized earth walls, and nearly 20,000 cubic yards of structural concrete, including multiple mass- concrete placements requiring strict temperature control. Despite a 400-day schedule and severe winter conditions, ESW completed the project on time in compliance with FAA requirements, earning the Kentucky Ready Mix Association’s “Excellence in Design” Award.
It was a pleasure to work with a company that was extremely knowledgeable, had the resources required to do the work, and refused to fail like this company. I only hope that should I have a project in the future with multiple problems, major schedule constraints, and significant concrete structures that E.S. Wagner will be there as the contractor.”
David Hunley, P.E., Vice President, Connico Incorporated
On the Ground
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